H-beam composite pile



June 26, 1951 J. H. THORNLEY' 2,558,529

H-BEAM COMPOSITE PILE Filed neo. 18, 194e 4 sheets-sheet 1 IN VEN TOR.

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H-BEAM COMPOSITE PILE Filed Dec. 18, 194s 4 sheets-sheet 4 Patented June26, 1951 UNITED STATES PATENT OFFICE H-BEAM COMPOSITE. PILE Joseph H.'rhorn1ey, Great Neck, N. Y.

Application December 18, 1948, Serial No. 66,017 1 claim. (ci. s1- 53)section, such as an H-beam, for the essential load-bearing structure.

, Composite piles employing wood bottom sections and concrete uppersections are known. One form of such piles is shown in my prior PatentNo. 1,954,188. The wood bottom section pile is generally employed insituations involving lighter loads. WoodV bottom sections are unsuitableif there is danger of the water table dropping below the tops of thesame.

Composite piles employing steel tubing lled with concrete as the lowersection and concrete upper sections have been satisfactorily constructedand installed. One form of such piles is shown in Patent No. 1,954,188.At present this type of pile is practically out of the question becauseof the cost and unavailability of steel pipe.

- The object of the present invention is to provide a composite pilebased on the use of a metal LA beam bottom section, and a concrete uppersection. An H-beam is preferable, but an equivalent heavy section may beused.

The embodiment of this concept in a practical structure and method ofinstallation involves the f overcoming of certain diniculties, but itsaccomplishment in the present invention produces certain importantadvantages not heretofore attainable by the prior art.

As to the former, I would call attention to the fact that while the artis quite familiar with the installation of piles consisting of VH -beamsthroughout, the driving of a short length of H- beam to form the lowerend of a composite pile is -a new feature and presents problems of itsown. While it is a relatively simple matter to guide `correctly a longH-beam in pile driver guides, and to drive the same straight, av shortsection of H-beam presents a 'different problem. Furthermore, thejunction of the top concrete section with the `H -beam bottom sectionpresents problems in both the matter of installation and the matter oftransfer of the load. My invention overcomes these diiculties simply andefliciently.

Certain unique advantages are attainable by the present invention, Aaswill be apparent from the following:

It iis known to drive full length H-beams for` building piles, andinstallations of the same are now in use. The steel beam in contact withan inert soil presents no problem. However, I have encountered instancesin which the soil conditions were found to be such that it wasinadvisable to use H-beam piles in direct contact with the soil becauseof the corrosive effect of the same. Where the site at which the H-beampiles are to be driven includes a ll of cinders, or has served as a dumpfor chemicals or corrosive refuse, it is not permissible, because of thelikelihood ofcorrosion, to put the steel H-beam piles in direct contactwith the soil. In the case of the cinder ll, the upper portion of thepiles down to a few feet below the lill where the pile entered thenatural soil which was neutral was protected by a jacket or coating.Wherever the soil conditions are such as to involve possible corrosionof steel in contact with the soil, jacketing of the H -beam withconcrete or some other material iscalled for. This involves additionaltime and expense and requires the use of extra material. An advantage ofsteel beam piles is the ease of installation by merely driving them toseat. Where they must be coated for part of their length, an expensiveand cumbersome method of installation is involved, and the cost ofmaterials is increased.

The pile of the present invention meets the requirements of such asituation. The lower H- beam section, cut to such a length as willinsure its being entirely below the bottom of such corrosive layers ofsoil, is driven down through and penetrates the corrosive layers ofsoil, and is disposed in a neutral soil and rests upon bedrock or inanother rm load-supporting stratum. The v concrete upper section, whichis of a variable length to conform to the inequalities of the rocksurface, extends through the corrosive Astrata down to and joins theH-beam section. While according to the preferred practice of the presentinvention, the concrete section is encased in a light corrugated steelshell, the shell is not or need not be gured as a load-carrying member,and may disappear without lowering the designed load-bearing ability ofthe pile. It serves primarily as a convenience in installing theconcrete shaft.

The concrete section may be provided with metal reenforcement toincrease its load-bearing ability within a given diameter. Suchreenforcement of a concrete column is per se well known in the art. Itmay comprise rods disposed longitudinally and circumferentially in theform of a cage or in such other form as may be preferred. The concreteitself is suiciently lresistant to such corrosive influences as exist incinder fills and dumps for various industrial wastes that aninstallation of piles of the present invention can be made where H-beampiles are not suitable. In installations of piles of the presentinvention it is not necessary to predetermine the length of the lightshelled section, but merely to assure that the H-beam section will beshort enough so that it will be wholly below the ocrrosive strata. Theuse of a long shell forming apparatus permits of wide variations in thelength of the light shelled section.

In the preferred form of the present invention, a heavy steel plate iswelded to and across the top end surface of the H-beam section. rIlhenupon the plate is erected and welded a short length of steel tubing longenough to form a coupling for connecting the H-beam section and theplunger or mandrel of a driving hammer. This permits the H-beam sectionto be more easilyhandled and to be guided while it is being driven inboth the initial stage and subsequent stages. This coupling may takevarious forms. In the preferred form, the short length of tubing weldedto the plate forms a socket into which the cylindrical end or point ofthe mandrel or driving member nts or telescopes. The relation of theparts may be reversed, i. e., the male part or stud of the coupling maybe welded upon the plate and the mandrel of the driving hammer mayprovide a socket fitting over the stud. Through this coupling the H-beamsection is guided and is driven. The same means which serves for guidingand driving the H-beam section serves also in the operation of makingthe junction between the light shell for the concrete section and forthe transfer of load from the concrete section to the steel beamsection.

The simplicity and convenience of this structure will be apparent tothose skilled in the art.

Now in order to acquaint those skilled in the art with the matter ofconstructing and operating my invention, I shall describe, in connectionwith the accompanying drawings, a specific embodiment of the same.

In the drawings:

Figure l shows, partlyin side elevation and partly in longitudinalvertical section, the pile of the present invention installed in place;

Figure 2 shows, in side elevation, the operation of driving the H-beamsection;

Figure 3 shows in side elevation and partly in section the mandrel andsleeve for the second stage of driving;

Figure 4 shows the mandrel removed and the helically corrugated lightshell for the concrete section installed in place inside the sleeve;

vFigure 5 is an enlarged cross sectional View showing the junction ofthe helically corrugated shell joined mechanically and in fluid tightrelation to the bottom section;

Figure 6 is a horizontal section taken on the line 6 6 of Figure 5- withthe shell omitted and showing the sealing gasket which forms the fluidtight junction between the bottom of the shell andthe plate on thebottom section;

Figure 7 is a top plan View of a modified form;

tom section will be accepted under the proposed New York City Code forloads up to sixty tons. I have had `experience in driving the same to alength of one hundred and twenty-five feet. There is no inherentlimitation as to length in the design. Such prior piles have usuallyconsisted of cased or uncased upper sections of concrete and lowersections of steel pipe oi 10% inches outside diameter and .279 inch wallthickness for loads up to sixty tons. The pile of the present inventionis suitable for loads and depths similar to those of the prior pilesabove mentioned, as well as for heavier loads, as will be laterdescribed.

The completed pile of the present invention, the preferred form of whichis shown in Figure l, comprises'the lower H-beam section I. Theparticular length of the H-beam section will be such, as indicated bythe borings previously taken, that together with the cased cast-in-placeconcrete section, it will bring the top ofthe composite pile `to thedesired bearing level. Where a particular layer or stratum of corrosivesoil is encountered care is taken to locate the H-beam section entirelybelow the same. For a pile intended to carry the above stated load, thebeam may be a twelve-inch, 53 pound H-beam which is a standard sectionon the open market. A steel plate 2, which in this case may be fourteeninches by fourteen inches by 3A inch thick or other suitable dimensions,is welded to the end face of the top of the H-beam section l. As shownin Figure 6, the rectangular plate is registered with the rectangularoutline of the H-beam. The plate may be circlar or polygonal in outlineif desired. To the top of the plate 2 there is welded a short couplingsection of pipe 3 which may, for example, be twelve to eighteen incheslong, 10% inches O. D. by 1/4 inch wall thickness, forming in efect anextension of the -H-beam section, as indicated in Figure 2. Thisconstitutes a unitary construction providing a socket by which the shortH-beam section may be guided and providing also .a driving face by whichthe section may be driven. f

Upon the outside of the pipe section-3 there are attached, as bywelding, lugs or projections 4 and 5 which are termed screw down lugs.They are shaped to enter the groove of the helically corrugated shell 6and serve as an interrupted male screw thread to permit the shell to bescrewed down against the top of the plate 2 with its lower end inengagement with the gasket or packing 1. The helically corrugated shell-6 and the short pipe length 3 attached to the plate 2 are filled withconcrete up to the top of the shell and provide a bearing face 8 uponwhich the load may be rested. Load transferring members of a structureto be carried in part by the pile may be connected to the upper end ofthe pile in known manner. As explained below, the concrete section maybe reenforced longitudinally and circumferentially by appropriatereenforcement rods and embedded inthe concrete of the shaft. Such`reenforcing rods may be extendedout of the upper face 8 to reenforcethe junction of a building frame member to the top of 'the concreteshaft. The rods may be combined with rings to form cages in well knownmanner.

The lower end of the bottom section l rests in this case upon bedrock l0at the surface 9, having been driven into engagement withL the same.

The gasket 'I may comprise a ring of 'rope which acts as a gasket tomake a liquid tight joint between the casing I1 and the plate -2 whenthe casing is applied as in Figure 3. The particular structure andformation of the gasket or packing 1 may be varied within the invention.Its function is the usual function of a gasket. By disposing the gasketI on the outside of the cylindrical socket member 3 the gasket cannotescape or become displaced when. the lower end of the shell 6 isthreaded down along the screw down lugs 4, 5 against the gasket. Thelower end of the shell 6 displaces the material of the gasket partlyinwardly and partly outwardly as it is thrust against the plate 2. Theinward movement is restrained by the socket member 3. The gasket isconstrained to remain in place to be engaged by the lower end of theshell 6 and it forms theV desired seal therewith. Preferably it isimpregnated with a bituminous compound.

The lower section unit, consisting of the H- beam section I, the plate 2and the socket 3 integrally united as by welding, is initially driveninto the ground in the manner indicated in Figure 2. The hammer I2 has amandrel or driver I3 attached to the base of the hammer. This mandrel I3fits inside of the pipe socket 3 and the pile section is therebyguidably attached to the base of the hammer. This permits the guidanceand control of the H-beam section which must be started in a definitelocation and kept plumb during driving.

After a number of these bottom sections have been driven toapproximately ground level, a pile driver equipped with a mandrel whichmay, for example, be of sixty to seventy foot length, indicated at l5 inFigure 3, and having its lower end or point I6 inserted in the socket 3,is employed to drive the section to seat. This mandrel is Surrounded bya sleeve of pipe I1 which is carried down with the plate 2 which forms aclosure for the lower end of the sleeve.

The mandrel I5 has its lower end I6 centered in the socket 3 and itcarries the sleeve I1 concentric with it and the socket 3 by means ofthe guiding projections I8 which form an interrupted ring about thesurface of the mandrel. At its upper end the mandrel has a centeringring I9 and an overhanging shoulder which carries the sleeve I1 downwith the mandrel. At its lower end the sleeve l'l rests upon and issealed by. the impregnated rope gasket 1. This keeps water and sand outof the space later to be occupied by grout and concrete. The drivingeffect upon the lower H-beam section is essentially through the mandrel,and is not required to be delivered through the sleeve Il which ismerely carried down with the mandrel to preserve a closed water-freebore within which the helically corrugated shell 6 may be lowered andattached to the H-beam section. The sleeve I1 is of an inside diametersuch that it will permit introduction of the helically corrugated shell6. After the particular pile section has been driven to refusal throughthe action of the hammer and the mandrel I5 with sleeve I1 as shown inFigure 3, the mandrel is withdrawn. The corrugated shell 6 is thenlowered inside the sleeve I1, and by means of a special wrench the shellis threaded over the screw down lugs 4 and 5 as shown in Figures 4 and 5to bring the lower end of the said shell into engagement with the gasket1.

Then the shell 6 receives a charge ofr grout and is filled up withconcrete. This cementitious filling is allowed to set in place. Thesleeve 6 and the socket 3 and the space between the socket and the shellare filled as indicated in Figure 1. The drive casing or sleeve I1 maybe withdrawn prior to filling the shell 6 with concrete or after thesame is done. The sleeve I1 is not intended to form any part of thefinished pile. Its purpose is to preserve the bore through the earth andto keep out extraneous matter until'the shell B can be set in place.

The sleeve I1 may be withdrawn any time after the shell 5 is-xed inplace, but the preferred practice is to lill the shell 6 with concretebefore pulling up the sleeve I1.

In the preferred practice, the sleeve I'I remains in place until thecorrugated shell 5 has been put in place and filled. In that practicethe tight closure made by the gasket l between the sleeve I1 and theplate 2 makes it unnecessary for the joint between the corrugated shell6 and the plate 2 to be fluid tight. Obviously, if the sleeve Il shouldbe withdrawn before the shell 6 is filled with grout and concrete, thenthe joint between the corrugated shell 6 and the plate 2 should be fluidtight.

By the above construction and procedure, the bottom section is underfull control at all times during the driving. The attachment between thetwo sections which is strong and effective even before the concrete hashad time to set, is capable of preventing separation by heaving. Thescrew threaded lugs 4 and 5 serve as a strong attachment between the twosections. -If desired, additional screw down lugs may be provided.`

While with the speciiic dimensions and construction -above described theload-carrying ability of the I-l-beam section may be greater than thatof the concrete section, this is not essential but optional. Thecomposite pile may readily be designed to provide a uniform loadcarrying ability throughout, equal to a full length H-beam pile. This isdone by properly designing the relative dimensions and reenforcement ofvthe concrete section and appropriate dimensioning the junction plate 2.

Suitable reenforcement, such as longitudinal rods 2E, attached tocircumferential or helical rods 25, may be disposed in the shell 6 withthe lower end thereof extending into the tubular tenon 3. Longitudinalrods may extend throughout the entire length of the concrete sha'ftandshorter longitudinal rods and circumferential rods disposed onlyV at thebottom of the concrete shaft, or at both the bottom and top, or, ifdesired, both longitudinal and circumferential reenforcing may extendthroughout the entire length of the shaft. The determination of thisreenforcement factor is within the skill of the designer. Suchreenforcing cage may lie inside the stud or tenon 3 or outside the same,as the design of the parts may dictate.

In Figures '7 and 8 I have illustrated a modified form of tenonconsisting in this case of a section of I-beam 28 welded to the top ofthe plate 2. This plate 2, as in the previous embodiment, is welded tothe upper end of the H-beam section I. Screw down lugs 29, 29 forcooperation with the corrugations of the shell 6 may be disposed atopposite corners or at all four corners of the I- beam section asillustrated in Figures 7 and 8. Where the modification of Figure 'lisemployed the base of the hammer and the lower end of the mandrel I6 mayhave an `appropriate fitting forked to extend over the web of the I-beamsection 28 to provide the necessary coupling between the H-beam sectionand the hammer and the mandrel. The driving hammer for the initialdriving of the H-beam section to ground level, and the lower end of themandrel I6 will in each case be provided with a suitable face orcoupling fitting the particular form of the tenon `28. The manner ofinstalling the H-beam and the concrete section superposed on the same isas described in connection with the preferred modification above.

In Figures 9 and 10, there is shown a further modified form of tenon forconnecting the driving mechanism during the driving of the H-beamsection, and for coupling the same to the concrete section above, asheretofore explained. Inthis case, the socket is formed as a rectangularbox section, preferably, but not necessarily, of two channel beamsections 39, 32, with the channelled sides facing each other, and havingtheir edges joined by welding, either with or without an additionalreenforcing strip 33 at the junction of the leading edges of thesechannel members. Instead of two pieces of channel, four pieces of angleiron may be utilized. In this case the driving hammer and the mandrel Iwill each have a suitable point tting in the generally rectangularsocket 34 formed on the insides of the two channel members. Suitablescrew down projections 29, 29 are provided at the corners of the stud ortenon for connection of the corrugated shell 5 thereto. The tenon membermay be made of rectangular section by welding four plates together attheir corners, or the tenon may be made up in any preferred manner toserve its functions in accordance with the foregoing teachings.

The manner of fastening the shell E down to the plate 2 may b-e varied,as I contemplate the use'of spring ngers fastened to the lower end ofthe shell, and bearing diagonally upwardly upon the sides of the stud ortenon, and acting like spring pawls to hold the shell down against theplate 2 by the gripping .action of the said spring ngers upo\ the side'walls of the stud or tenon.

Where such spring iingers are used, the driving hammer and also themandrel may t over the outside of the tenon or stud instead of insideof, the same. The reenforcing cage may, in such case,lbe disposed in theannular space between the shell and the stud or tenon.

In thepile of the present invention, the H- beam section I is drivenahead of the driving sleeve Il. The plate 2 serves as a connectionb;tween the lower beam section and the upper concrete section vfor whichit serves as a closure. During driving, it serves to close off the lowerend of the driving sleeve from the outside. Thus the plate 2 serves toconnect the upper and lower sections mechanically, but it also serves tosegregate them.

Since the beam section is driven ahead of the driving sleeve and doesnot require to be passed through the driving sleeve, as in the case ofthe projectile pile, its cross sectional dimensions do not depend uponthe cross section of the bore of the driving sleeve. This allows ofvariation in design of the shape, cross section and dimensions of thebeam section quite independently of the concrete section.

The load carrying abilit of the concrete section may be brought up tothat of thebeam section by suitable rod and cage or other metallicreenforcement, so that substantially maximum emciency of utilization ofmaterials in both sections may beeifected. The load bearing ability ofthe beam section may, in some installations, be substantially higherthan that of the concrete section, without introducing undue increase inl' cost, because the beam section may be relatively short. Thus,forexample, if it is desired to provide a larger beam section crosssectional area for bearing upon bedrock or other stratum, the short beamsection may be selected accordingly at no great additional expense,

I do not intend to be limited to the precise details shown or described,nor to the dimensions stated, since these have been given by way ofillustration and not of limitation.

The simple and rugged construction herein disclosed provides a highlysatisfactory means for guiding and driving the \lower section, and foranchoring the two sections rmly together for all necessary purposes.

I claim:

In combination, a lower pile section comprising a metal beam having atransverse plate on the upper end of the same, a socket member on top ofsaid plate said member having screw down lugs, a mandrel having a lowerend fitting the socket for guiding the lower pile section and drivingthe same into the ground, said mandrel having a shoulder spacedlongitudinally from said plate for engaging the upper end of a sleeve,and a sleeve of fixed length between said shoulder and the plate saidplate closing off the lower end of the sleeve, said mandrel havingcentering vmeans for centering the sleeve relative to the socket topermit a shell to be lowered in the sleeve .and threaded onto said lugs.

JOSEPH I-I. THORNLEY.

REFERENCES CITED The following references are of record 'in the le ofthis patent:

UNITED STATES PATENTS Number Name Date 1,954,188 Thornley Apr. 10, 19342,099,664 Watt Nov. 16, 1937 2,168,459 Upson Aug. 8, 1939 2,200,524 WattMay 14, 1940 2,326,155 McCook Aug. 10, 1943 2,450,879 Kohn NOV. 18, 1947

